CONTENTS INTRODUCTION PHYSICAL PROPERTIES OPTIX FEATURES DURAPLEX FEATURES OPTIX PHYSICAL PROPERTIES TABLE DURAPLEX PHYSICAL PROPERTIES TABLE FABRICATING ACRYLIC SHEET CARE CUTTING MACHINING CUTTING & MACHINING TIPS ANNEALING FINISHING OPERATIONS CEMENTING & FASTENING DECORATING & PAINTING FORMING METHODS 6 6 6 7 8 8 8 9 10 11 OUTDOOR SIGNAGE ROLL STOCK SPOOL DIMENSIONS TRANSPORTING ROLL STOCK DETERMINING SHEET THICKNESS DETERMININING SHEET SIZE SIGN ASSEMBLY 13 13 13 14 14 14 TROUBLE SHOOTING GUIDES
PLASKOLITE FABRICATION GUIDE INTRODUCTION PLASKOLITE acrylic sheet is an excellent choice for a variety of industries, including: signage, store fixture, P.O.P. display, skylight, building/window, hobby/ craft, lighting, and the automotive aftermarket. PLASKOLITE is a leading manufacturer of acrylic sheet, acrylic resin, polystyrene sheet and acrylic mirror sheet products. Since 1950, it has built an excellent reputation for providing superior quality products and responsive customer service.
OPTIX FEATURES OPTIX acrylic sheet can be used continuously in a temperature range of 170-190°F. OPTIX acrylic sheet begins to soften between 210-220°F and starts to melt between 300-315°F. OPTIX acrylic sheet can withstand temperatures down to -20°F without noticeable changes in properties. ET ACR YL 40 20 300 Figure 1 IC SHE 60 340 OPTIX TEMPERATURE RESISTANCE LASS OPTIX acrylic sheet is one of the most durable thermoplastic materials for resisting scratches.
38304.1_32 4/30/04 4:15 PM Page 4 (Black plate) ACRYLIC SHEET PROPERTIES Optix® Acrylic Sheet Properties Units ASTM Test ASTM Method Physical Properties Test Method Specific Gravity Units 1.19 D-542 1.49 Optical Refractive Index Light Transmittance Total Haze E 90-70 E 90 E 413 Sound Transmission %% %% 92 92 22 db 27 db E 413 % D-570 By weight % D-570 Water Absorption By Weight Shrinkage D-702 D-702 % % Shrinkage Shrinkage Mechanical Mechanical Tensile Strength - Max.
MPACT MODIFIEDACRYLIC ACRYLI PACT MODIFIED Impact Modified Acrylic Flat Sheet ® ACRYLIC SHEET PROPERTIES Impact Modified Impact Modified Acrylic FlatAcrylic SheetSheet ® Physical Properties PROPERTY ASTM TestModified Units Impact Acrylic Sheet ASTM Method UNITS ® ® 30% I30% SG ® I 50% 50% I SG05 I ® 70%I 70% I ® 100% 100% I I SG10 Optical Optical 92 90 D-1003 90 92 Light transmission % 92 92 Light TransmittancePercent haze D-1003 % 92 92 90 90 2 <3 I D-1003 <3 I 2 30% I % 250% I PROP
cutting tool, or Fletcher Terry Knife. Score to penetrate 1/3 through the sheet. Align the score with the edge of the table and apply gentle pressure to break the sheet along the score line (See Fig. 2). CARE SAFETY CONCERNS Acrylic sheet is a combustible thermoplastic, it will ignite and burn if placed in open flame or in contact with any other source of ignition. When storing or working with acrylic sheet, please be aware of the thermoplastic properties and consider fire precautions.
Circle routers can cut round parts by securing the acrylic sheet to a turntable, then rotating the sheet around the stationary router. Computer Numerically Controlled (CNC) routers are used for high volume, intricate, precise acrylic parts. The part is designed on a CAD/CAM system and geometry is programmed directly into the CNC machine. Many of the variables; feed rate, RPM, bit diameter, depth of cut are adjustable for optimum cutting performance.
Mills can be used to create precisely machined parts. designed with proper geometry for cutting acrylic sheet. Use proper and constant feed rates, and RPMs. To prolong tool/blade life, apply the fastest feed rate that gives a satisfactory edge. Eliminate vibration of the acrylic sheet through clamping or other hold-down methods. Align all fences and tables parallel to the cutting device. Machine PLASKOLITE acrylic sheet with a conventional cut rather than a climb cut.
SANDING BUFFING All methods of sanding will result in the removal of machining marks, and produce a matte finish. The choice of hand, palm, random orbit, disc, belt, or drum sanding, depends on the quantity, size and shape of the acrylic sheet. Like sanding wood, work from coarse to fine paper. Use light pressure, and keep the part or sander moving to avoid heat build up (See Fig. 11). After sanding, the edge is ready for buffing or flame polishing.
CAPILLARY CEMENTING MECHANICAL FASTENING This technique allows solvent cement to flow into the joint and melt the parts together. Apply cement with a syringe, solvent applicator, or eyedropper. Use small weights, fixtures, and fences to hold the parts in place (See Fig. 14). Initial bonding occurs within 5-10 seconds. A three hour cure time is sufficient to allow further fabrication, and 24-48 hours for maximum bond strength.
SPRAY PAINTING can be accomplished. Certain restrictions, such as heating temperature and time, depth of draw, and thickness of vinyl affect the quality of the end product. Refer to Vinyl film manufacture’s guidelines for more detailed information. Use an atomizing spray gun system that will uniformly distribute paint free of water and oil. The use of backlighting will aid in determining the uniformity of paint application (See Fig. 16).
THERMOFORMING PLASKOLITE acrylic sheet is heated to its forming temperature, placed over a mold, creating an air- tight seal. Vacuum is drawn through the mold, pulling the sheet to it. Once the part takes the shape of the mold, it is slowly cooled, then released. Typical for signage, Figure 20 shows a method for low volume production. The acrylic sheet is heated while on the mold, vacuum applied. Angle iron presses out any webbing or wrinkles on the flange, and prevents any vacuum loss during cooling.
USING PLASKOLITE ACRYLIC FOR OUTDOOR SIGNAGE INTRODUCTION Topics related specifically to sign fabrication are presented in this section. Use this portion of the guide, in conjunction with the PLASKOLITE acrylic sheet fabrication guide, to minimize production problems. Along with flat sheet, PLASKOLITE offers OPTIX SG acrylic sheet, DURAPLEX SG05, and SG10 impact modified sheet in roll form. A wide range of sizes and thicknesses are available. PLASKOLITE Sign Grade sheet offers many benefits.
ACRYLIC SELECTION mum sign temperature* (°F) - room temperature (°F)) X 0.00004. Calculate contraction by taking: Measurement between channels (inches) X (room temperature (°F) - minimum temperature (°F)) X 0.00004. A simple calculation is to allow 1/16” per linear foot for expansion and contraction. Note: * Maximum sign temperature must remain below acrylic deflection temperature (See physical property tables, pages 4 & 5).
Figure 25 Figure 27 If mechanical fasteners must be used, allow room for expansion and contraction. A method of attachment to prevent acrylic sign faces from binding on the sign cabinet include a spacer, slightly taller than the thickness of the acrylic sheet and the sign cabinet combined, inserted through the oversized hole and slot (See Fig. 26). VENTILATION To prevent sign face distortion caused by heat build up above the acrylic deflection temperature, cabinet ventilation should be incorporated.
TROUBLE SHOOTING GUIDES SAWING DEFECT CAUSES Chipping on edge of sheet Feed rate is too fast Teeth on blade are bent Vibration of stacked sheets Melting of acrylic Dull blade Feed rate is too slow Incorrect blade angle Stopping of sheet while sawing CEMENTING DEFECT CAUSES Crazing in machined edge Stress due to machining of cemented joint Edge polishing Chemical attack by cement Cloudy joints Excessive moisture Poor joint strength Bubbles Dry spots
SCREEN PRINTING DEFECT CAUSES Poor detail Screen mesh too coarse Paint too thin Worn screen Paint drying on screen Hot, dry weather Large lapse of time between screening Crazing Stress from fabrication Flame polishing THERMOFORMING SOLUTION Use a finer mesh Reduce thinner additive Replace screen Add retardant to slow paint drying Flood screen between passes Review fabrication methods Flame polish as last step DEFECT CAUSES Bubbles Overheating Moisture Uneven
CHEMICAL RESISTANCE of PLASKOLITE ACRYLIC SHEET NO ATTACK ATTACK Alum, Ammonium Alum, Potassium Aluminum Fluoride Aluminum Sulfate Ammonia Gas Ammonium Carbonate Ammonium Chloride Ammonium Hydroxide Ammonium Phosphate Ammonium Sulfate Antimony Trichloride Barium Chloride Barium Hydroxide Barium Sulfide Battery Acid (10%) Benzoic Acid Boric Acid Calcium Hypochloride Carbonic Acid Citric Acid Copper Chloride Copper Sulfate Detergent Solution Diesel Oil Diethylene Glycol Ethylene Glycol Fatty Acids Ferrous C
SUGGESTED VENDORS Weld-On 3 Quick set, good bond strength, SAW BLADES most aggressive. Avoid use in high stess areas. FS Tool Corp. 800-387-9723 P.O. Box 510 210 S. 8th St. Lewiston, NY 14092-0510 Weld-On 16 Fast drying, high strength. Weld-On 40 Reactive gluing system. Good for bonding PLASKOLITE acrylic to other materials. Lord Corp. Chemical Products 800-458-0434 P.O. Box 10038 2000 West Grandview Blvd. Erie, PA 16514-0038 406/19 Medium set time for acrylic to acrylic.
DISCLAIMER This manual is a general guide for working with PLASKOLITE OPTIX® acrylic and DURAPLEX® impact modified acrylic sheet. Because actual results vary with differences in operating conditions, thickness, color, and composition of the acrylic sheet, nothing contained herein can be construde as a warranty that PLASKOLITE’s acrylics will perform in accordance with these general guidelines.
Worldwide Support Plaskolite maintains manufacturing and distribution facilities in Columbus, OH; Zanesville, OH; Compton, CA; Riverside, CA; Olive Branch, MS; Monterrey, MX; Grand Saline, TX; and Doesburg, Holland, for fast product delivery and local support of its distributor network.
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